operating instructions translation of the original instructions · 2017. 8. 16. · sihi range:...

SIHIRange: ZTND Volute casing pump for heat transfer oils PUMP DESCRIPTION SERIAL NUMBER

For local contact details:

www.sterlingsihi.com

In the search to improve continuously its products,

Sterling Fluid Systems reserves the right to modify

its products at any time without prior notice © (Sterling Fluid Systems BV) 2009

Operating instructions Translation of the original instructions

Safety issues Chapter 1

Intended application Chapter 2

Planning the installation Chapter 3

Unpacking, storage, handling Chapter 4

Installing the pump Chapter 5

Start up and shut down Chapter 6

Maintenance, dismantling and assembly Chapter 7

Troubleshooting Chapter 8

Technical data Chapter 9

Connections, dimensions, sectional drawing Chapter 10

Declaration of conformity. Example Annex I

ATEX information Annex II

Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical personnel only and these installation, commissioning and operating instructions must be strictly observed. Failure to do so could result in:

• danger to you and your colleagues,• the pump or the pump unit may be damaged,

Note that the manufacturer is not liable for damages resulting from failure to observe these instructions. Please be aware of your responsibility to your colleagues when working on the pump or the pump set!

Safety instructions marked with included in this Operating Instructions and in the Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to be considered in particular when operating this pump in potentially explosive atmospheres!

Safety issues Page 1 of 3 Chapter 1




Sterling Fluid Systems reserves the right to modify its

products at any time without prior notice. (Sterling Fluid Systems BV) 2009

1. Safety

This operating manual gives basic instructions,

which must be observed during installation,

operation and maintenance of the pump. It is

therefore imperative that this manual is read by

the responsible personnel/operator(s) prior to

assembly and commissioning. It must always be

kept available at the site of pump installation.

It is not only the general safety instructions

contained in this chapter “Safety” which must be

observed, but also the specific information

provided in the other chapters.

1.1 Identification of safety symbols in the operating instructions

Safety symbols are given in these operating

instructions. Non compliance with these would

affect safety and are identified by the following

symbol

Danger symbol as per DIN 4844-W9

(ISO 3864 - B.3.1)

Or in case of danger of electric current with:

Danger symbol as per DIN 4844 W-8

(ISO 3864 - B.3.6)

The word

ATTENTION

identifies those safety regulations where non-

compliance may pose a danger to the pump and

its function. It is imperative that the appropriate

safety information is attached to the pump/pump

set, for example:

• an arrow indicating the direction of rotation• symbols indicating fluid connections• the identification plate

and that these are kept legible.

1.2 Qualification and training of personnel

The personnel responsible for operation,

maintenance, inspection and assembly must be

adequately qualified. The scope of responsibility

and supervision of the personnel must be exactly

defined by plant management. If the staff do not

have the necessary knowledge, they must be

trained and instructed. This task may be

performed by the machine manufacturer or

supplier on behalf of the plant management.

Moreover, plant management must ensure that

the contents of the operation instructions are fully

understood by plant operators and other relevant

personnel such as maintenance staff.

1.3 Hazards in case of non compliance with safety instructions

Non compliance with the safety instructions may

result in risk to personnel as well as to the

environment and the pump/pump set and result in

the loss of any right to claim damages.

For example, non-compliance may result from, or

lead to, the following:

• failure of important functions of the pump/pumpset/plant

• failure of specified procedures of maintenanceand repair

• exposure of people to electrical, mechanicaland chemical hazards

• danger to the environment owing to hazardoussubstances being released.

1.4 Compliance with regulations relating to safety at work

When operating the pump the safety instructions

contained in this manual, the relevant national

accident prevention regulations and any other

service and safety instructions issued by plant

management must be observed.







1.5 Safety instructions relating to operation • If high or low temperature pump/pump set

components involve hazards, steps must be

taken to avoid accidental contact.

• Guards for moving parts (e.g. couplings) must not be removed from the pump/pump set while

in operation.

• Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must

be drained safely so as to prevent any risk to

persons or the environment. Statutory

regulations are to be complied with.

• Hazards from electricity are to be avoided by the user (see for example the VDE-

specifications and the bye-laws of the local

power supply utilities).

1.6 Safety instructions relevant for maintenance, inspection and assembly work It is the plant management’s responsibility to

ensure that all maintenance, inspection and

assembly work is performed by authorized

personnel who have adequately familiarised

themselves with the subject matter by studying

this manual in detail.

Any work on the machine must only be performed

when it is at a standstill. It is imperative that the

procedure for shutting down the machine

described in this manual is followed.

Pumps and pump sets, which convey hazardous

media, must be decontaminated.

On completion of the work all safety and

protective guards must be re-installed and made

operative again. Prior to re-starting the machine,

the instructions listed under “first commissioning”

are to be observed.

1.7 Safety instructions for the use in areas with explosion hazard

In this section information is given for operation in

areas where an explosion hazard exists.

1.7.1 Complete pump sets If the pump is combined with other mechanical or

electrical components in one set, the category of

the complete unit will correspond, based upon the

Directive 94/9/EC, only to that category with which

all of its components comply.

Note:

These comments are of particular importance

when pumps, which conform to a given category

of Directive 94/9/EC, are powered by a driver

which is not in the same category.

Although the pump may bear the Ex sign, the set

should not be used in areas with an explosion

hazard when the motor is not classified for this

application.

This means that plant management personnel

should always check that all elements of the set

comply with the Directive 94/9/EC.

1.7.2 Execution of coupling guards Coupling guards that are to be used in areas with

an explosion hazard, have to fulfil one of the

following criteria:

• consist of non-sparking material, e.g. brass. • if they consist of sparking material, e.g. steel

sheet, they must be designed in such a way

that the rotating parts will not come in contact

with any part of the guard if errors, that could

be foreseen, are committed by the user, e.g if

a person steps on the guard.







1.7.3 Monitoring technical parameters

When using pumps in areas with an explosion

risk, the operator must check the following

parameters regularly:

• leakage of shaft seals • bearing temperature • that the pump is always filled with liquid during

operation

• that the pump does not operate against a closed valve for any length of time.

The operator must ensure that pumps, which

show evidence of abnormal operation, are

switched off and not started again until the cause

of the abnormal operation has been eliminated.

1.7.4 Avoiding external damage In areas with a risk of explosion the operator must

ensure that the pumps and or pump set is not

subjected to external impacts e.g by heavy

objects.

1.8 Unauthorized alterations and production of spare parts Modifications may be made to the pump/pump set

only after consultation with,and written approval

from, the manufacturer. Using spare parts and

accessories authorized by the manufacturer are in

the interests of safety. Use of other parts may

exempt the manufacturer from any liability.

1.9 Unauthorized mode of operation The reliability of the pump/pump set can only be

guaranteed if it is used in the manner intended

and in accordance with the instructions of this

manual. The specified limit values must under no

circumstances be exceeded.

1.10 Warranty / guarantee Sterling Fluid Systems guarantee satisfactory

operation if:

• the pump is installed and operated in compliance with these instructions and in

operating conditions approved by Sterling Fluid

Systems

• modifications are only undertaken with Sterling Fluid Systems’ written agreement.

Intended application Page 1 of 3 Chapter 2






2. Application The pump is to be used only for the operating

conditions stated by the customer and confirmed

by the supplier. Guarantee is assumed within the

scope of the Sterling Fluid Systems conditions

of sale.

Appropriate application and operating conditions

are contained in the attached data sheets.

2.1 Warning of misuse

• Do not touch hot pumps. • The pump may only be used for the

application(s) stated. Otherwise hazards for

people and environment may arise.

• Never subject the pump to a temperature shock. Never spray off the hot pump with

cold liquid.

• Do not exceed fluid density stated. Otherwise, there is a danger of motor

overload.

• The pump must not be operated beyond its characteristic curve – otherwise there is a

danger of cavitation and motor damage.

2.2 Accessories The accessories included in the scope of supply

are indicated in the delivery note or in the order

confirmation. The corresponding operating and

installation instructions are also indicated in the

Annex relating to accessories.

If it is intended to mount other accessories on the

pump or on the pump set, please inform the

manufacturer in advance in order that appropriate

technical advice can be given.

2.3 Construction and mode of operation

ZTN pumps are volute casing pumps with nominal

outputs and flange dimensions acc. to EN 733 /

DIN 24255. They have especially been developed

for pumping mineral and synthetic heat transfer

oils. The pumps are applicable in installations with

and without inlet pressure.The back pull out

construction allows the disassembly of the

complete insert unit without removing the pump

out of the pipe system.

Impurities up to a grain size of 0,1 mm can be

handled, but shorten the service life.

ATTENTION







2.4 Description Type size

Hydraulic + Bearing

Shaft seal

Material design

Casing gasket

• A First hydraulic • B Second hydraulic • D Transnorm size with double volute • A one ball bearing respectively two inclined ball bearing grease lubricated and one liquid flushed sleeve bearing

002: radial shaft seal rings (Viton) GBC: unbalanced standard mechanical seal

1B: Spheroidal cast iron GGG40.3, cast iron GG25 impeller 2B: Cast steel

2: confined flat gasket of graphite with A4 insertion

ZTND

032125 to

200500

A All D 200400, 200500 B 32160, 32200 A

Alternatively 002, GBC

1B 032125 to 200315 2B 200400, 200500

2

Example of a pump designation:

1-3 4 5-7 8-10 11 12 13-15 16-17 18

ZTND 032 250 A A GBC 1B 2

Casing gasket

Execution material

Shaft sealing Bearings: A

Impeller size

Nominal discharge

Pump series

Hydraulic: A/B/D







2.5 Shaft sealing Depending on the application, different shaft

sealing executions are offered (see 2.4)

• Radial shaft seals (execution 002) or mechanical seals according to DIN 24960 are

utilised in the following cases:

• if the pump draws from a suction line, • if the pump is fed by a feed line with a

pressure of less than 0.5 bar or

• if the pumped liquid is at or near its boiling point.

Section 2.4 does not contain the codes for all

variations of mechanical seals. Where the code is

not included or replaced by QQQ, consult the

relevant data sheet of the mechanical seal

supplier (e.g. special execution of the mechanical

sealing in a back to back position).

ATTENTION

Planning the installation Page 1 of 2 Chapter 3






3. Planning the installation

3.1 Piping system

• Note the arrows on the pump branches indicating the direction of flow.

• Choose nominal widths of the pipelines according to the nominal widths of the pump

branches or larger ones with the

corresponding reductions.

• Flange sealing must not protrude on the inside.

• Ensure that the pipework is clean before installing of the pump.

• Support the pipework in order to avoid distortions at the pump components (risk of

damage to pump components)

• Avoid abrupt changes of cross section and direction.

• Where different diameter pipework is to be used, connection should be by eccentric

transition pieces. This will avoid the formation

of air pockets in the pipework.

• For difficult pumping on the suction side, to stabilise the flow, a pipe length 15 times the

diameter of the suction branch should be

installed before the suction branch.

• The flow rate in the suction line or inflow line, must not exceed 2 - 3 m/s.

3.1.1 Suction line / inflow line See the sketches below for the optimum layout of

pump installation for flow and suction lift

operation.

positive suction head operation suction lift operation

Ensure that air pockets cannot be created.

Unequal nominal widths of the suction branch and

suction line must be compensated by eccentric

transition pieces.

Connection of eccentric pipe transitions

It is recommended that a filter is installed in front

of the pump with a filter surface of at least 3 times

the pipe cross section (approx.100 meshes/cm²).

A shut-off valve should be installed in the feed

line. It must be closed for maintenance work.

It should be installed in order to avoid air pockets

forming in the spindle cap, i.e. with the spindle in

a horizontal position or pointing vertically

downward.

3.1.2 Discharge line The discharge line is to be laid steeply, a constant

cross section should be aimed at.

For flow regulation, a valve must be installed

behind the pump. If non-return valves are used,

they should close smoothly. Pressure shocks

must be avoided.

3.1.3 Leakage line For the controlled draining of leakage (required by

DIN 4754) it is recommended to install a leakage

line (see 5.10). For this purpose a connection

bore of the size G ¼ is provided.

ATTENTION

Planning the installation Page 2 of 2 Chapter 3






3.1.4 Inlet and outlet connections The various connecting points are shows in the

drawings. (See Annex, Chapter 10, point 10.1).

3.1.5 Pressure control For consistent control of pressure, it is advisable

to install in the pipework a measuring point in front

of, and behind the pump.

3.2 Electrical connections For the drive motor a mains connection is required

which complies with the European Regulations

and Directives for the Standards in Industry and

with the instructions of the local power supply

utilities of the country concerned.

Unpacking, storage, handling Page 1 of 1 Chapter 4






4. Unpacking, storage, handling

4.1 Safety measures

• Never stay below the suspended load. • Keep a safe distance while the load is being

transported.

• Use only approved lifting appliances, which are in good condition.

• Adjust the length of the lifting appliances in such a way that the pump and/ or the pump

set, is suspended horizontally.

• Do not use the eyebolts on the pump components for lifting the assembled pump or

the complete set.

• Do not remove documents, which are attached to the pump.

• Do not remove the protection covers from the pump suction/discharge. Otherwise, there

may be a risk of contamination.

4.2 Unpacking Before unpacking, a visual check of the packing is

recommended. If transport damage is visible, the

extent should be noted on the receipt or on the

delivery note. Potential claims must be lodged

immediately with the carriers or the insurance

company.

4.3 Interim storage If the pump or the pump unit is not installed

immediately after delivery, it must be stored free

from vibration in a dry room.

4.4 Handling The pump or pump set must be lifted and handled

as shown in the following sketches.

Pump without motor

Pump set

4.5 Protection against corrosion In general, a protective coating is applied to the

whole pump, internally.

4.5.1 Removal of protection The protective coating is compatible with normal

thermal oils. The operator must ensure that the pump is

completely free of water.

Installing the pump Page 1 of 3 Chapter 5





products at any time without prior notice.

(Sterling Fluid Systems BV) 2009

5. Installing the pump

5.1 Requirements The pump and the pump set, must have been

unpacked and handled as described in Chapter 4.

5.2 Use of trained staff Only appropriately trained staff must undertake

the work described in this chapter.

5.3 Safety measures

• Connect the pipework carefully to prevent the pumped liquid escaping during operation and

endangering operating personnel.

• Ensure that the suction or inflow line, and the discharge line are closed by valves.

• Ensure that all electrical connections are “dead”. Otherwise, there is a risk of electric

shock.

• Pay attention to relevant internal plant regulations.

• Avoid accidental contacts with hot components.

ATTENTION

• The operator must ensure that the pump, internally, is clean, not contaminated and free

of water.

5.4 General information

5.4.1 Assembly tools Special tools are not required for assembly and

installation.

5.4.2 Permissible ambient conditions The ambient temperature can be from -20 °C to

+60 °C. The atmospheric humidity should be as

low as possible in order to avoid corrosion.

5.4.3 Base, foundation The pump must be installed on a flat floor or

foundation free from vibration. In case of doubt

use vibration dampening feet.

The pump set must be correctly mounted on the

foundations. To avoid distortion of the pump set

and/or the foundation, parallel shims must be

used between the base plate and foundation.

Prior to installing, checks should be made with

regard to:

- Possible damage to the pump or the

pump set that may occur in transit.

- Ease of running ( check that the shaft is

free to rotate by hand ).

- The foundation dimensions.

The following preparatory work must be carried

out before to placing the pump:

- Roughen and clean foundation surface.

- Remove shuttering / cores from the

anchor holes.

- Blow the anchor holes clean.

- Check the position and dimensions of

the anchor holes against the arrangement

drawing.

5.4.4 Installation of the set The complete set mounted on the base plate must

be placed on the foundation with its foundation

(rag) bolts hanging below the baseplate.

5.4.5 Space required The space required for the pump set is set out in

the foundation plan or installation drawing.

Ensure easy access to the shut-off and regulation

valves as well as to any measuring instruments.








5.4.6 Position In principle the ZTN pumps are installed

horizontally.

5.5 Motor Before assembly check the direction of rotation of

the motor (indicated by an arrow on the pump

casing). If this is not possible the direction of

rotation of the complete unit can only be checked

only if the pump is filled. Only motors with axial

ventilation are permitted.

In any event, the operating instructions of the

motor manufacturer must be followed, since the

motor is generally incorporated by STERLING

FLUID SYSTEMS into the pump set.

5.6 Alignment of the set Place shims under the base plate on both sides of

the foundation bolts, 10 mm from the base plate

edge. Use a spirit level to align the set.

If necessary, place shims between the foundation

bolts to prevent the base plate from sagging. Care

should be taken to minimize distortion of the base

plate during installation. The location of the driver

must not be higher than that of the pump. The

max. deviation from the shaft centre line is ± 0,1 mm.

The foundation bolts should be embedded in

concrete using quick-setting grout.

5.7 Coupling Install the coupling avoiding hard blows, if

necessary in warm condition. Arrange the pump

and motor on a level base. The shaft ends must

be aligned exactly. The distance between each

half of the N-EUPEX B ( FLENDER ) coupling

must be 2 - 3 mm (see fig.).

If other manufacturers’ couplings are used, follow

the manufacturer’s instructions. After installation

on the foundation and connecting the pipework,

the coupling alignment must be checked and re-

aligned, if necessary. Moreover, after reaching the

operating temperature the alignment of the

coupling must be checked again.

The coupling requires a guard that meets DIN

31001 in order to avoid accidental contact during

operation.

In any event, the operating instructions of the

coupling manufacturer must be followed, since the

coupling is a component incorporated by Sterling

Fluid Systems.

ruler

The following is required a = a1 and b = b1

5.8 External cold oil If the pump is operated in suction lift operation,

the pressure has to be measured at the vent bore

(see fig. in chapter 6).

In case of underpressure cold oil (e.g. Level-Oiler)

has to be admitted onto the shaft seal via the

connection Uio (G ¼). The borehole UAL has to be

closed. By this measure is ensured that air cannot

enter the system and the seal does not run dry.

The standard value for the necessity of this

measure is an underpressure of abt. 0,5 bar in the

inflow line near the pump.








5.9 Checking before installation Before installing the pump on the plant, the

following points must be checked:

1. Is the electrical current to the drive motor

switched off?.

2. Are suction and discharge lines emptied and

closed by valves?.

3. Is it possible to rotate the pump easily by

hand (for this purpose turn the fan of the

motor or the coupling)?.

4. Have the latest internal/plant instructions been

observed?.

5.10 Mounting the pump and installation into pipework

The following instructions must be carried out:

1. Remove the protective covers from the pump

flanges and the auxiliary pipework

connections.

2. Correctly insert the flange seals.

3. Connect the suction or feed line.

4. Connect the discharge line.

The pump must be aligned with the pipework. The

pipework must be supported so that distortion

cannot occur when connecting the pump.

5.11 Connection of the leakage line It is necessary, a tube must be connected to the

bore UAL G ¼” for draining off, without any danger,

heat transfer liquid which possibly leaves.

5.12 Final work The following final steps must be undertaken:

1. Check the tightness of the connecting flanges.

2. Check for easy running of the pump (for that

purpose turn the motor fan or the coupling).

3. Check the coupling alignment.

4. Install the coupling guard.

5.13 Hydrostatic pressure test When subjecting the piping system to a

hydrostatic pressure test, exclude the pump from

the pressure test.

If it is not possible to test the pipework without the

pump, ensure that foreign material cannot enter

the pump.

• The max. permmisible pressure for a pressure test is 1,3 times the nominal

pump pressure.

• The nominal pump pressure is indicated in the tecnical data sheet.

• The medium for the pressure test should be heat transfer oil.

• For reasons of operating safety it is not permitted to subject the pump to a

pressure test using water.

Uio

Starp-up and shut-down Page 1 of 3 Chapter 6







6. Start-up and shut-down operations

6.1 Requirements The pump or the pump set, must be installed acc.

to the instructions of Chapter 5.

6.2 Use of trained staff Only appropriately trained staff must carry out the

work described in this chapter.

6.3 Safety measures

• Electrical connections must be made according to the European Regulations and

Directives for the Standards in Industry and in

compliance with the instructions of the local

power supply utilities of the country

concerned.

• Only appropriately authorised personnel may carry out this work.

ATTENTION

• Fill the pump correctly; otherwise the shaft seal could be destroyed.

• Fill the supply lines correctly. • Check the direction of rotation only when the

pump is filled.

• Fill the pump slowly if hot media are being pumped in order to avoid distortions or heat

shock.

• When handling explosive, toxic, hot, crystalline or corrosive media, ensure that

there is no risk to people or the environment.

• Control the output at constant speed at the discharge side only. The valve at the suction

side must always be completely open during

operation to avoid the risk of cavitation.

• If there is no bypass line, do not run the pump with the control valve closed for any

length of time.

• Safety measures should be taken by the end user to ensure (for example by

means of a relief valve) that the

permissible pump casing pressure is not

exceeded during operation

• Repeat the alignment of the coupling at operating temperature. Re-align the pump

or the motor, if necessary.

6.4 Filling / ventilation Before the first start-up the pump as well as the

suction or inflow line, respectively, must be

completely filled with pumping medium in order to

avoid dry operation of the pump. It can take

several minutes to ventilate the pump completely

as the heat transfer oil is very viscous when it is

cold. For the ventilation of the pump remove the

vent screw shown below and rescrew it only when

heat transfer oil leaves bubble-free.

ATTENTION

An incomplete ventilation can shorten the service

life of the pump.

6.5 Electrical connection The motor must be connected at set out in the

circuit diagram in the terminal box.

6.6 Checks before switching-on Before switching on the pump unit, the following

points should be checked:

Vent screw








1. Is all pipework connected and are the unions

tight?

2. Is the pump including the pipework filled

properly?

3. Is the shut-off valve in the discharge line

closed?

4. Is the shut-off valve in the suction line

completely opened?

5. Is the motor ready for operation?

6. Is the direction of rotation of the motor

correct?

(check by running the motor for a short time)

7. Is the coupling aligned exactly?

8. Has the shaft seal been installed?

9. Are the supply lines, if any, to the shaft seal

open?

10. In the case of oil lubrication - has the bearing

housing been correctly filled with oil?

11. Is the pump completely ventilated? 6.7 Start-up operation For starting proceed as follows:

1. Open fully the valve on the suction side

2. Close the valve on the discharge side

3. Switch on the motor

4. Check the pressure gauges at the pressure

measuring points

If the pumping pressure does not increase

consistently with increasing speed, switch off the

motor again and vent the pump one more.

5. After reaching operating speed, regulate the

operating point of the pump by adjusting the

valve in the discharge line (see technical data

for permissible range of operation).

Pumping against a closed valve in the discharge

line is permitted only if a minimum output via a

bypass line is guaranteed.

By means of safety measures at the plant (e.g.

overflow valve) it must be ensured that the

admissible casing pressure of the pump is not

exceeded because of malfunction during

operation.

The alignment of the coupling should be repeated

at operational temperature. If necessary the pump

or the drive motor, respectively, is to be re-

aligned.

6.8 Switching frequency Size Permissible number of

starts equally spaced per hour

032125, 032160, 032200, 032250, 040125, 040160, 040200, 040250, 040315, 050125, 050160, 050200, 050250, 050315, 065125, 065160, 065200, 065250, 065315, 080160, 080200, 080250, 080315, 100160, 100200, 100250, 100315, 125200, 125250, 150200, 150250

8

150315, 150400, 150500, 200250, 200315, 200400, 200500

6

6.9 Special instructions During operation the following points must be

observed:

- Control the speed and the delivery head

- Ensure that the pump runs without vibration

- Control the liquid level in the suction line and/or

inflow tank

- Control the bearing temperature (max.

temperature 100 °C)

- Control the cooling flow from the motor to the

shaft seal.

- Shaft seal: As a rule leakages of some cm³/h at

shaft seals occur as vapour or fog. Additionally

slight drop leakages can occur.

ATTENTION

If the leakage increases considerably after the

running-in procedure of the shaft seal, the pump

must be switched off as soon as possible, and the

shaft seal has to be checked.

6.10 Shutting-down Before shutting down close the regulating element

at the discharge side.

After shutting down all regulating elements can be

closed. If there is the risk of freezing, dismount the

pump and then drain it by turning it upside down.








In case of handling explosive, toxic, hot,

crystalline or corrosive media it must be ensured

that persons and environment are not

endangered. Even if the pump was turned upside

down residues remain in the pump. For transport

the pump must be free from any dangerous

matters. In case of long standstill periods the

pump is to be preserved.

Maintenance, dismantling and assembly Page 1 of 7 Chapter 7







7. Maintenance, dismantling and assembly

7.1 Requirements The pump or the pump set must have been shut

down in the manner described in Chapter 6.

7.2 Use of trained staff Only appropriately trained and skilled staff should

undertake the work described in this chapter.

Only authorised personnel must undertake

electrical work associated with maintenance of the

pump/pump set.

7.3 Safety measures

• For explosive, toxic, hot, crystalline as well as different pumping media esure that people

and the environment are not endangered.

• Flush the pump with clean liquid before dismantling.

• The working place for disassembly or assembly must be clean.

• Before reinstallation, the pump must be free of any dangerous material.

7.4 Maintenance and inspection The pump requires only little maintenance.

7.4.1 Bearing with grease lubrication The antifriction bearing should be lubricated

through greese nipples 63.60 at the following

intervals:

Pump speed Lubrication interval

1450 ≤ n ≤ 2900 rpm 2000 operating hours

n ≥ 2900 rpm 700 operating hours

As lubricant should be used lithium-saponified

grease which is free from resins and acids and

which protects against rust.

Properties:

- Consistency as per DIN 51818, class 1

- Fulling penetration DIN ISO 2137 (0,1 mm)

310-340

- Application temperature 140 °C

- Dropping point 250°C, DIN ISO 2176

In our works the antifriction bearings are

lubricated with the grease Microlube GL 261

(manufacturer Klüber ). After approx. 10000 hours

of operation in case of permanent operation, or

after two years in case of intermittent operation,

the antifriction bearing is to be dismounted,

washed out and to be provided with a new grease

filling.

If another suitable grease shall be applied, the

residues of the former grease must be entirely

eliminated from the bearing and the bearing

chamber.

In case of especially unfavourable conditions of

operation (humidity, dust and/or high ambient

temperatures) the lubrication intervals must be

considerably shorter.

The quantity of grease required is:

Bearing bracket Grease (g)

25 9

35 15

45 22

grease nipple








7.4.2 Inner sleeve bearing The inner sleeve bearing does not require any

maintenance. Abrasive particles in the pumping

medium cause wear and shorten the service life.

7.4.3 Shaft seals • For shaft seal execution “002” The radial seal rings should have little or no

visible leakage. Where there is considerable

leakage, check the radial seal rings.

• For shaft seal execution “CDC” and “GBC” The mechanical seal should have little or no

visible leakage. Where there is considerable

leakage, check the mechanical seal.

7.4.4 Drive motor The drive motor must be maintained according to

the instructions of the manufacturer.

7.5 Dismantling

7.5.1 Preparation for the dismantling Proceed as follows:

• Disconnect power to the motor • Drain the plant, at least within the pump area,

i.e. between the valves on the suction and

discharge side

• If necessary, disconnect any measuring probes or control devices and remove them

• The pump casing must not be detached from the pipe union

• Remove motor mounting bolts and move the motor so that there is sufficient space to

remove the back pull out unit. When using a

spacer coupling repositioning of the motor is

not necessary.

• Dismantle guard coupling, pump feet and coupling.

7.5.2 Replacement parts The item numbers necessary for ordering spare

parts are provided in the component parts list in

the Annex.

In any case the flat gasket item No. 40.00 is to be

replaced when the pump is assembled again.

7.5.3 Dismantling the pump

7.5.3.1 Bearing bracket 25 and 35

1. Mark the position of the parts to each other by

a colour pen or by a scribing point.

fig. 1

2. Detach the nuts 92.00 and remove the

washers 55.00.

Take safety measures for supporting the complete

mounting unit and catch oil possibly flowing out.

3. Remove the complete insert unit out of the

pump casing 10.20 and take off the gasket

40.00 (fig. 1)








• For shaft seal execution “002”

fig. 2

4. Detach the shaft nut 92.20 and take off the

safety tab washer 93.10. (fig. 2)

5. Dismount the impeller 23.00 and the key

94.01.

6. Detach the hexagon screws 90.13 of the

bearing bracket 33.00 and take off the cover

16.10 incl. shaft seal casing 44.11.

7. If required the shaft seal casing 44.11 is to be

dismounted by detaching the screws 91.40 and

removal of the disks 55.02.

8. Remove the key 94.00, detach the hexagon

screws 90.10 and dismount the bearing cover

36.00.

9. Push the shaft 21.00 together with the

antifriction bearing 32.10 out of the bearing

bracket 33.00.

fig. 3

10. Take off the circlip 93.20 by means of a burst-

off pliers and pull the antifriction bearing 32.10

and the spacer 52.50 from the shaft 21.00. (fig. 3)

• For shaft seal execution “CDC” and “GBC”

fig. 2




94.01.



16.10 incl. shaft seal casing 44.10. The seal

cover 47.10 can remain in the bearing bracket.

7. Mark the position of the locating ring 48.50 on

the shaft. (fig. 3)

fig. 3

8. Dismount carefully the locating ring and the

mechanical seal 43.30.

9. If required the casing of the mechanical seal

44.10 can be dismounted by detaching the

screws 91.40 and removal of the disks 55.02.

Furthermore the seal cover 47.10 can be

removed out of the bearing bracket 33.00 by

means of a lever.


screws 90.10 and dimount the bearing cover

36.00.








11. Push the shaft 21.00 together with antifriction

bearing 32.10 out of the bearing bracket 33.00.

fig. 4

12. Take off the circlip 93.20 by means of a burst-

off pliers and pull the antifriction bearing 32.10

and the spacer 52.50 from the shaft 21.00.

(fig. 4) 7.5.3.2 Bearing bracket 45

1. Mark the position of the parts to each other by

a colour pen or by a scribing point.

fig. 1

2. Detach the nuts 92.00 and remove the

washers 55.00.

Take safety measures for supporting the complete

mounting unit and catch oil possibly flowing out.

3. Remove the complete insert unit out of the

pump casing 10.20 and take off the gasket

40.00 (fig. 1)

• For shaft seal execution “002”

fig. 2




94.01.



16.10 incl. shaft seal casing 44.11.

7. If required the shaft seal casing 44.11 is to be

dismounted by detaching the screws 91.40 and

removal of the disks 55.02. Dismount clamping

disc 50.60.


screws 90.10 and dismount the bearing cover

36.00.

9. Push the shaft 21.00 together with the

antifriction bearing 32.11 out of the bearing

bracket 33.00.

fig. 3


safety tab washer 93.11. Then pull the inclined

ball bearing 32.11 and the spacer 52.51 from the

shaft 21.00. (fig. 3)








• For shaft seal execution “CDC” and “GBC”

fig. 2




94.01.



16.10 incl. shaft seal casing 44.10. The seal

cover 47.10 can remain in the bearing bracket.

7. Mark the position of the locating ring 48.50 on

the shaft. (fig. 3)

fig. 3

8. Dismount carefully the locating ring and the

mechanical seal 43.30.

9. If required the casing of the mechanical seal

44.10 can be dismounted by detaching the

screws 91.40 and removal of the disks 55.02.

Dismount clamping disc 50.60. Furthermore

the seal cover 47.10 can be removed out of the

bearing bracket 33.00 by means of a lever.


screws 90.10 and dimount the bearing cover

36.00.

11. Push the shaft 21.00 together with antifriction

bearing 32.11 out of the bearing bracket 33.00.

fig. 4


safety tab washer 93.11. Then pull the inclined

ball bearing 32.11 and the spacer 52.51 from the

shaft 21.00. (fig. 4) 7.6 Post dismantling activities

7.6.1 Hints for cleaning. • Clean all parts. • Clean the clearances and sealing surfaces

with an appropriate liquid.

7.6.2 Points to be checked The following pump parts are to be checked:

1. Check the shaft seal for damage and wear.

2. Check the wear ring surfaces for damage and

wear. The difference in diameter between the

wear ring at the impeller and the casing parts

shall be 0,3 mm to 0,5 mm. If the wear rings

are worn out too much, they have to be

replaced.

3. The flat gaskets 40.00 and 40.01 have to be

replaced in any case.

4. Check the O-rings 41.20 and 41.24 and

replace them, if necessary.








7.6.3 Repair of the shaft seal • For shaft seal execution “002” Defective radial seal rings 42.13 must be removed

carefully out of the sealing chamber without

damaging the wall.

As the sealing rings have a thin metal shell it is

recommended to push a sharp tool (e.g. a small

sharpened screw driver) between the casing wall

and the sealing ring shell. Then deform the ring by

bending up it until the ring can be taken out. (see

fig. 5)

fig. 5

Then clean the sealing chamber and grease it

slightly. If the shaft shows grooves in the area of

the radial seal rings, the sealing rings are to be

mounted acc. to fig. 6.

The distances “x” and “y” apply to the

corresponding seal diameter “d“.

255 4< 2< 2

Ø d x2535

34

y

yx

d

fig. 6

Fig. 7 shows the original mounting of the radial

seal rings.

55 535 4

325xØ d

d

x

fig. 7

Use a mounting taper plug (accessory) for the

assembly.

The sealing lips must show to the inside and only

the last ring points outwards. The spaces between

he sealing rings are to be provided with high

temperature grease (see 7.4).

7.6.4 Repair of the bearing bush In case of wear the bearing bush must be

replaced completely with the appertaining steel

sleeve. It must be pulled out with an inside

withdrawal device. After pressing in the new bush

ensure that it fits exactly.

ATTENTION

The concentricity tolerance of the bearing bush

with regard to the cover centering at the outside

diameter must not exceed 0,05 mm.

7.7 Assembly 7.7.1 Tightening torque When tightening the bolts the following torques

must be used:

Thread M6 M 8 M10 M12 M16 M20

Tightening torque 8,5Nm 12Nm 25Nm 40Nm 90Nm 175Nm

Tightening torque

casing nuts 92.00

65Nm 90Nm








7.7.2 Pump assembly • For shaft seal execution “002”

Carry out the following steps:

1. Assembly of the shaft unit acc. to fig. 3.

ATTENTION

For bearing bracket 45, mount the inclined ball

bearing according to fig 8.

fig. 8

2. Assembly of the insert unit acc. to fig. 2.

When assembling pay attention to the position

of the vent screw 90.30 with regard to the

bearing bracket 33.00.

3. The casing seal is effected by a special flat

gasket 40.00. Push the insert unit into the

volute casing acc. to fig. 1; tighten with 65 Nm.

• For shaft seal execution “CDC” and “GBC” Carry out the following steps:

1. Assembly of the shaft unit acc. to fig. 4.

ATTENTION

For bearing bracket 45, mount the inclined ball

bearing according to fig 8.

fig. 8

2. Assembly of the insert unit acc. to fig. 2.

Under assembly the seal cover 47.10 with the

vent screw 90.30, as shown in the fig.9, has to

be fitted into the bearing bracket 33.00.

fig. 9

The setting of the mechanical seal can be seen on

fig. 10.

fig. 10

∅d a 25 175,5

35 237

55 307

3. The casing seal is effected by a special flat

gasket 40.00.

4. Push the insert unit into the volute casing acc.

to fig. 1; tighten with 65 Nm.

Troubleshooting Page 1 of 1 Chapter 8







8. Help in case of trouble

8.1 Use of trained staff Trouble shooting must be undertaken only by appropriately trained personnel.

8.2 Symptoms, causes and remedies

Symptom Cause Remedy - Counter pressure too high Check the plant for contamination.

Regulate anew the operating point. - Pump or pipeline, resp., not completely filled

vent and fill the pump as well as the suction or inflow line resp.

- Suction lift too high or positive suction head too low

Check the liquid levels, open the shut-off elements at suction side. Clean the filters and dirt traps installed at suction side.

- Sealing gap too large because of wear Replace the worn pump parts. - Wrong sense of rotation Modify the motor connection.

Output too low

- Casing or suction line leaky Replace the casing seal. Check the flange connections.

- Casing, shaft seal, foot valve or suction line leaky

Replace the casing seal. Check the shaft seal. Check the flange connections.

- Suction lift too high or positive suction head too low


Pump does not prime or only intermittently

- Loose or jammed parts in the pump. Open and clean the pump. - Casing screws not correctly tightened. Check the tightening torque of the casing

screw. - Radial seal rings leaky. (only for 002) Check the condition of the rings as well as

the friction surface of the shaft, if necessary replace the rings.

- Mechanical seal leaky. (only for CDC, GBC)

Check the sealing surfaces and elastomers of the mechanical seal. In case of damage, replace the mechanical seal.

Pump leaks

- Seals defective Replace the seals. - Pump or pipeline not completely filled. Vent and fill the pump as well as the

suction line or inflow line, resp. - Suction lift too high or positive suction head too low


Temperature of the pump increases

- Pump is operated against closed gate. Open the shut-off element at discharge side.

- Pump or pipeline not completely filled. Vent and fill the pump as well as the suction line or inflow line, resp.

- Suction lift too high or positive suction head too low.


- Pump is not properly leveled or it is distorted.

Check the pump installation.

- Foreign matters in the pump Dismount and clean the pump.

Pump runs noisily

- Antifriction bearing or sleeve bearing defective

Replace parts.

- Pump is not properly leveled or it is distorted.

Check the pump installation.

- The admissible operating conditions were not complied with

Observe the operating conditions stated in the data sheet.

Motor protection switch switches off

- Loose or jammed parts in the pump. Open and clean the pump.

Technical data Page 1 of 4 Chapter 9







• All indicated operating limits are not valid for all liquids which can be pumped. See

technical data or delivery note.

9. Technical Data For technical information about the pump or pump

set, which is not described in this chapter, see the

specific data sheet. Note that data relating to a

specific order may conflict with information

provided here. In any such case, the order

specific information will override data provided in

the general technical documentation.

Pressure component operating limits:

Material Temperature Pressure Sizes

0ºC to 120ºC 16 bar

120ºC to 300ºC 13 bar 1B


032125 to 200315


120ºC to 300ºC 13 bar 2B


200400 to 200500

Shaft sealing operating limits:

Shaft sealing execution Temperature range

002 -25°C to +200°C

GBC -40°C to +150°C

Heat barrier / shaft sealing / bearing tempeture

trend in normal operation:

Flange locations:

Axial suction flange, discharge flange radially

upwards.

Flanges:

Material design 1B and 2B: Complies with DIN

2533 PN16.

Direction of rotation:

Clockwise seen from the drive end of the pump.

Materials of construction, and of shaft seals:

See Chapter 2.4.

Vibrations:

ZTN range pumps comply with VDI 2056 and ISO

5199 Class K for pumps with a driving power of up

to 15 kW and Class M with a driving power of

more than 15 kW

Noise levels:

The noise levels of the pump comply with the

Directive 001/30 - 1992 of the EUROPUMP

Commission.

The following table provides approximate values:

P (kW)

LWA (dB)

pump without motor

Note that additional noise can be generated by:

• The driver. • A possible misalignment of the coupling. • Pipework (note: the larger the pipe diameter,

the lower the pipe noise).

ATTENTION

Technical data Page 2 of 4 Chapter 9







Permissible branch forces and moments:

• Material execution 1B:

DN Fy Fz Fx ΣΣΣΣF My Mz Mx ΣΣΣΣM flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)

32 580 725 638 1131 522 609 754 1102 40 580 725 638 1131 522 609 754 1102 50 783 957 870 1508 580 667 812 1189 65 1189 1450 1305 2291 667 754 928 1363 80 1189 1450 1305 2291 667 754 928 1363 100 1566 1943 1740 3045 725 841 1015 1508 125 2349 2900 2610 4553 1015 1189 1450 2117 150 2349 2900 2610 4553 1015 1189 1450 2117

To

p b

ran

ch

z-A

xis

200 3132 3886 3480 6061 1334 1537 1885 2784 50 870 783 957 1508 580 667 812 1189 65 1305 1189 1450 2291 667 754 928 1363 80 1305 1189 1450 2291 667 754 928 1363 100 1740 1566 1943 3045 725 841 1015 1508 125 2610 2349 2900 4553 1015 1189 1450 2117 150 2610 2349 2900 4553 1015 1189 1450 2117 200 3480 3132 3886 6061 1334 1537 1885 2784

En

d b

ran

ch

x-A

xis

250 3457 3132 3874 6055 1462 1694 2065 3799

• Material execution 2B: (Only for 200400 to 200500 pump sizes) Multiply by ƒ = 1,276; which is the relationship of E – modules between GS-C25 and GGG 40.3

Permissible forces and moments for 1B and 2B executions. According to

ISO/DIN 5199 Class II (1997) Annex B.

Techical Data Page 3 of 4 Chapter 9







DN flanges

Fy (N)

Fz (N)

Fx (N)

ΣF (N)

My (Nm)

Mz (Nm)

Mx (Nm)

ΣM (Nm)

150 5638 6960 6264 10927 2436 2854 3480 5081 Top branch z-axis

200 7517 9326 8352 14546 3202 3689 4524 6682

200 8352 7517 9326 14546 3202 3689 4524 6682 End branch x-axis 250 8352 7517 9326 14546 3202 3689 4524 6682

Maximum permissible speeds:

max. speed

n = 3600 rpm size

max. speed

n = 3000 rpm size

max. speed

n = 1800 rpm size

max. speed

n = 1500 rpm

size

t = 120 °C

032125 032160 032200 040125 040160 040200 050125 050160

050200 065125 065160 065200 080160 080200 100160 100200

t = 120 °C

032250 040250 050250 065250 080250 100250 125200

t = 120 °C

040315 050315 065315 080315 100315 125250 150200 150250

150315 150400 200250

t = 120 °C

150500 200315 200400

t = 350 °C

032125 032160 032200 040125 040160 040200 050125 050160

050200 065125 065160 080200 100160

t = 350 °C

040250 050250 065200 065250 080160 080250 100200 100250

t = 350 °C

040315 050315 065315 080315 100315 125200 125250 150200

150250

t = 350 °C

150315 150400 150500 200250 200315 200400 200500

The maximum speeds result from the permissible peripheral speeds of the impellers or from the shaft load admissible at

higher temperatures, respectively.

Techical Data Page 4 of 4 Chapter 9







Operating range:

(Continuous operation)

Sizes

0,3 Qopt < Q < 1,1 Qopt 032125 to 080315

100315 150250 to 150500

0,5 Qopt < Q < 1,1 Qopt

100160 to 100250 125200 to 125250

150200 200500

0,7 Qopt < Q < 1,2 Qopt 200250 to 200400

This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical

properties are handled, it may be necessary to narrow the permissible operating range.

See the specific performance curve for more details.

Connections, dimensions, sectional drawing Page 1 of 9 Chapter 10







10. Connections, dimensions, sectional drawing 10.1 Connections Connections for bearing brackets 25, 35

ufg : Grease filling connection. uio : Sealing liquid connection. uAL : Drainage for leakage. uv : Vent connection

Size ufg uv uio uAL

032125 032160 032200 032250 040125 040160 040200 040250 040315 050125 050160 050200 050250 050315 065125 065160 065200 065250 065315 080160 080200 080250 080315 100160 100200 100250 100315 125200 125250 150200 150250

G 1/8 G 1/8 G 1/4 G 1/4








Connections for bearing brackets 45

ufg : Grease filling connection. uio : Sealing liquid connection. uAL : Drainage for leakage. uv : Vent connection

Size ufg uv uio uAL

150315 150400 150500 200250 200315 200400 200500

G 1/8 G 1/8 G 1/4 G 1/4








10.2 Table of Dimensions ZTN 032-125 ... 150-250

size DN2 DN1 a b c f h1 h2 m1 m2 n1 n2 s1 s2 w w1 x d1 l t u

032125 112 140 190 140 105

032160 132 160 120

032200

80 50

160 180

100 70 240 190

137

0322501)

32 50

100 65 180 225 125 95 320 250 164

040125 112 140 210 160 105

040160 80

132 160 240 190 120

040200

50

160 180

100 70

265 212 140

040250 100

15 360

180 225 320 250

267

164

80 24 50 27 8

0403151)

40

125 65

18 470 225 250 125 95

345 280 340 204 100 32 80 35 10

050125 132 160 240 190 105

050160 180 130

050200

50 160

200

100 70 265 212

150

050250

100 15 360

180 225 320 250

267

164

80 24 50 27 8

0503151)

50

65

125 18 470 225 280 345 280 340 210 100 32 80 35 10

065125 180 140

065160 160

200 280 212

147 80

065200

65

360

180 225

125 95

320 250

M12

267

165

24 50 27 8

065250

100 15

200 250 360 280 185

065315

65 80

80 18

470 225 280

160 120 400 315

M16 340 220

32 80 35 10

080160 360 225 320 250 267 163 24 50 27 8

080200 65 15 180

250 125 95

345 280 M12

180

080250 200 280 200

080315

80 100

250 315 400 315

235

100

1001601) 200 140

100200

125

200 360 280 202

100250 225

280

212

100315

100 125 120

1252001) 315 242

140

125250 125 150

140

80 18

250

355

160 120

400 315

M16

236 120

150200 550 450 271 190

1502501) 150 200 160 100 20

470

280 400 200 150 500 400

M20

M12

340

273 170

32 80 35 10

1)Transnorm pump sizes, not included in DIN 24255/ EN 733. Flanges drilled according to ANSI 150 can be suplied.

DN 2








Dimension table ZTN 150-315 ... 200-500

size DN2 DN1 a f h1 h2 m1 m2 i l x d1 w c s1 s2 n1 n2 n3 n4 n5

1503151) 315 400 160 100 320 360 290 330 60

1504001) 355 450 35 M12

380 420 340 380

1505001)

150 200 180

400 500 M16 425 460 385 420

2002501) 250 335 425 M12 340 410 300 370

2003151) 355 450

45

360 420 320 380

2004001) 375 500

180 120

35 400 460 360 420

80

2005001)

200 250 200

670

425 560 220 160 50

110 180 48 500 23 M20

M16

475 575 425 525 100

1)Transnorm pump sizes, not included in DIN 24255/ EN 733. Flanges drilled according to ANSI 150 can be suplied.

Flange connection size acc.

to DIN EN 1092-2

PN 16

*Flange connection size

acc. to DIN EN 1092-2

PN 25

DN2/DN1 32 40 50 65 80 100 125 150 200 150 200 250

D 140 150 165 185 200 220 250 285 340 300 360 425

k 100 110 125 145 160 180 210 240 295 250 310 370

bfl 18 18 20 20 22 24 26 26 30 34 34 36

+4 +4,5 Tolerances

-3 -4

d2 x 19x4 19x4 19x4 19x4 19x8 19x8 19x8 23x8 23x1 28x8 28x12 31x12








10.3 Parts list When ordering spare parts give the following information: position number, the complete pump designation and the serial number, which can be found on the nameplate fixed to the pump. Pos. Nr. Description 10.20 Volute casing 16.10 Cover 18.30 Support foot 18.31 Support foot 21.00* Shaft 23.00* Impeller 32.10* Grooved ball bearing 32.11* Inclined ball bearing 33.00 Bearing bracket 36.00 Bearing cover 40.00* Gasket 40.01* Gasket 41.10 Joint 41.20* O-ring 41.24* O-ring 42.10* Radial shaft seal ring 42.13* Radial shaft seal ring 43.30* Mechanical seal 44.10 Shaft seal casing 44.11 Shaft seal casing 47.10 Sealing cover 48.50 Locating ring 50.20 Wear ring 50.60 Clamping disc

Pos. Nr. Description 52.50* Spacer 52.51* Spacer 54.51* Bush 55.00 Disc 55.01 Disc 55.02 Disc 56.00 Grub screw 63.60 Grease nipple 90.10 Hexagon screw 90.11 Hexagon screw 90.12 Hexagon screw 90.13 Hexagon screw 90.22 Stud 90.30 Screwed plug 90.31 Screwed plug 90.40 Grub screw 91.40 Allen head screw 92.00 Hexagon nut 92.01 Hexagon nut 92.02 Hexagon nut 92.20* Shaft nut 92.30* Shaft nut 93.10* Lock washer 93.11* Lock washer 93.20* Circlip 94.00* Key 94.01* Key * Recommended spare parts








ZTN 032125 to 150250 SHAFT SEAL EXECUTION “002”

33.0

092

.20 9

3.10

23.0

094

.01

54.5

140

.00 1

6.10

44.1

1 42.1

341.2

0 42.1

093.2

0 92.0

118

.30 5

5.019

0.12

52.5

094.

0021.

0036

.00

90.1

032

.10

63.6

090

.31

41.1

090

.30

91.4

055

.02

40.0

190

.13

90.2

292

.00

55.0

010

.20








ZTN 032125 to 150250 SHAFT SEAL EXECUTION “GBC”

43.3

0

33.0

092

.20 9

3.10

23.0

094

.01

54.5

140

.00 1

6.10

42.1

093.2

0 92.0

118

.30 5

5.019

0.12

52.5

094.

00

21.0

036

.00

90.1

032

.10

63.6

090

.31

91.4

055

.02

40.0

190

.13

90.2

292

.00

55.0

010

.20

47.1

041

.24

48.5

0

41.2

041

.10

90.3

044

.10 9

0.40








ZTN 150315 to 200500 SHAFT SEAL EXECUTION “002”

92.2

0

92.3

0

90.1

1

94.0

110.

20

23.0

040.

01

40.0

0

90.1

3

16.1

055

.02

91.4

0 33.

00

44.1

141

.10

90.3

090

.31

63.6

0 32.

11

90.1

0 36.

00

21.0

0 94.

00

93.1

1

90.1

2

55.0

1

92.0

1

18.3

052

.51

42.1

0

41.2

0

42.1

3

50.6

0

92.0

0

55.0

0

90.2

2

18.3

1

54.5

1

56.0

0

50.2

0

93.1

0

92.0

2








ZTN 150315 to 200500 SHAFT SEAL EXECUTION ”GBC”

92.3

0

48.5

0 41.

24

43.3

0

92.2

0

93.1

1

90.1

1

94.0

110.

20

23.0

040.

01

40.0

0

90.1

3

16.1

055

.02

91.4

0 33.

0041

.10

90.3

090

.31 63

.60

32.1

1 90.

10

36.0

0 21.

00

94.0

0

52.5

1

90.1

2

55.0

1

92.0

1

18.3

042

.10

41.2

0

47.1

050

.60

92.0

0

55.0

0

90.2

2

18.3

1

54.5

1

56.0

0

50.2

0

93.1

0

92.0

2

44.1

0 90.

40

Declaration of conformity. Example Page 1 of 1 Annex I







ATEX information Page 1 de 11 Annex II





its products at any time without prior notice. (Sterling Fluid Systems BV) 2009

Supplementary operating instructions in accordance to EC directive 94/9/CE (ATEX) for the use in potentially explosive atmospheres of the following pumps types, manufactured by Sterling Fluid Systems (Spain), S.A. type:

ZLN, ZLK and ZLI (Industrial pumps)

ULN (Self Priming Pumps) ZTN, ZTK and ZTI (Thermal Oil Pumps)

ZHN, ZDN, ZEN and ZLI (Hot Water Pumps)

These supplementary operating instructions give only general instructions for the use of pumps in conditions that need explosion protection. The operating instructions of the specific pump must be taken into consideration as well. Contents Page

1 General objective 2 2 Safety issues 2 2.1 Identification of safety symbols in these operating instructions 2 2.2 Compliance with regulations 2 2.3 Qualification and training of personnel 3 2.4 Safety instructions for maintenance, inspection and installation work 3 3 Instructions concerning pump and accessories 3 3.1 General 3 3.2 Pump pressure containment components 3 3.3 Coupling and coupling guard 3 3.4 Belt drive 3 4 Instructions concerning installation and start-up of pump sets 3 4.1 Coupling 3 4.2 Connection to power supply 3 4.3 Earthing 4 4.4 Belt drive 4 5 Instructions concerning operation and maintenance 4 5.1 Unauthorized modes of operation 4 5.2 Explosion protection 4 5.3 Pump filled and vented 4 5.4 Marking 4 5.5 Fluid pumped 5 5.6 Checking of direction of rotation (see also pump specific operating manual) 5 5.7 Pump operating mode 5 5.8 Temperature limits 5 5.9 Maintenance 7 6 Additional instructions for couplings in ATEX pump sets 7 6.1 Limitations 7 6.2 Storage 7 6.3 Installation 7 6.4 Mounting coupling parts 8 6.5 Alignment 8 6.6 Fixing the coupling on the shaft 9 6.7 Operation 9 6.8 Maintenance 9 6.9 Figures 10







1 General Objective

Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to select the pump with the correct category for this zone. The pump installation and operation must take into account the Operating Instructions that are described in these supplementary operating instructions. They contain important information for safe and reliable pump operation in hazardous areas. This information plus all information given for all components of the system (e.g. the operating instructions for the pump) are of vital importance to avoid risks. These supplementary operating instructions do not take into account national or local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel in charge of the installation. For any further information or instructions exceeding the scope of this manual or in case of damage, please contact Sterling Fluid Systems nearest customer service. 2 Safety issues These supplementary operating instructions contain fundamental information concerning all actions with pumping systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and maintenance. Therefore these and all other instructions related to safety must be known and available with easy access to all personnel involved in the above stated actions. Not only must the general safety instructions established in this chapter on “Safety issues” be complied with, but also the safety instructions outlined under specific headings as well as the safety instructions contained in the specific operating manual of the specific pump. 2.1 Identification of safety symbols in these instructions In these supplementary operating instructions, the safety instructions related to explosion protection are marked with:

The sign

is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions. 2.2 Compliance with regulations It is imperative to comply with the safety instructions contained in these supplementary operating instructions, the operating instructions of the pump type concerned, the relevant national and international explosion protection regulations, health and safety regulations and the operator’s own internal work, operation and safety regulations.

Ex symbol relates to additional requirements, which must be complied with when the pump is operated in hazardous areas. In addition the following must be observed:

If pumps / units are located in hazardous areas, it is imperative to make sure that the correct category of pump and equipment is selected and that unauthorised modes of operation are prevented. Non-compliance may result in first: increased risk of explosion and second: the specified temperature limits might be exceeded. Non-compliance with these safety instructions may also result in the loss of any rights to claim damages.

Non-compliance may also result in hazards to persons by explosion.







2.3 Qualification and training of personnel The personnel responsible for or involved in the installation, the operation, maintenance and inspection of the pump and the unit must be adequately qualified to carry out these works in hazardous areas. The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the staff does not have the necessary knowledge, they must be trained and instructed. The pump manufacturer or supplier on behalf of the plant management may perform this task. Moreover, plant management must ensure that the contents of the operation instructions are fully understood by plant operators and other relevant personnel such as maintenance staff. 2.4 Safety instructions for maintenance, inspection and installation work The operator is responsible to assure that all installation work, inspection, operation and maintenance must be carried out by authorized and qualified specialist personnel, which is thoroughly familiarized with the pump operating instructions and these supplementary operating instructions.

If necessary, additional explosion protection regulations must be considered. 3 Instructions concerning pump and accesories 3.1 General Pumps and accessories for installations in hazardous areas must comply with the relevant category of mechanical and electrical equipment. Some details are pointed out below: 3.2 Pump pressure containment components

For handling inflammable fluids, the pump pressure containment components must be made of ductile material. 3.3 Coupling and coupling guard The accident prevention regulations require, that pump drive must not be operated without a coupling guard. If a customer specifically decides, not to include a coupling guard in our delivery, then the operator must provide such coupling guard himself. The coupling must be selected and sized in accordance with the instructions of the coupling manufacturer. It is important to make sure that the materials selected for coupling and coupling guard are non-sparking in the event of mechanical contact. Sterling Fluid Systems scope of supply meets this requirement.

In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be considered. 3.4 Belt drive Belts must include some electrically conductive material. 4 Instructions concerning installation and start-up of pump sets In addition to the normal installation instructions, the specific criteria for explosion protection are listed below: 4.1 Coupling

The coupling must be installed, started-up and operated in accordance with the operating instructions of the coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and motor bearings. It has to be ensured that the coupling halves are correctly aligned at all times. 4.2 Connection to power supply

Only a properly trained electrician must effect connection to the power supply. The available main voltage must be checked against the data on the motor rating plate and an appropriate start-up method must be selected.







Sterling Fluid Systems strongly recommends using a motor protection device (motor protection switch)

In hazardous areas, compliance with national and local regulations form and additional requirement for electrical connections. 4.3 Earthing

To eliminate risks due to electrostatic charging, pump set must be earthed directly or through an earthing line. 4.4 Belt drive

Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly. 5 Instructions concerning operation and maintenance 5.1 Unauthorized modes of operation The warranty related to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance to its designated use as described in the following sections of this supplementary operating manual and the specific pump operating manual. The limits stated in the data sheet must not be exceeded under any circumstances.

Any operation of the pump outside the permissible operating range and any unauthorized modes of operation may result in the specific temperature limits being exceeded (see section 5.8). 5.2 Explosion protection

If pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is required, the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no excuse, to ensure explosion protection. 5.3 Pump filled and vented Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions have to be taken to prevent dry running.

It is necessary that the system of suction and discharge lines and thus the wetted pump parts including seal chamber and auxiliary systems are completely filled with fluid to be handled at all time during pump operation, so that and explosive atmosphere is prevented.

If the operator cannot warrant this condition, appropriate monitoring devices must be used. Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas bubbles may be collected in the pump and cause the mechanical seal to run dry.

High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure) may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal to run dry. Suitable monitoring facilities shall be installed, if necessary.

For design inherent reasons, however, it is not always possible to exclude the existence of a certain residual volume not filled with liquid after the pump has been filled prior to start of operation. However, once the motor is started up the pumping effect will immediately fill this volume with pumped fluid.

It is imperative to make sure that seal chambers and auxiliary seal systems are properly vented from air and filled with liquid. 5.4 Marking

The Ex marking on the pump only refers to the pump part, i.e. the

operating instructions translation of the original instructions · 2017. 8. 16. · sihi range:...

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